c Installation Instructions Clamp Open Guard Kits 6008230-12V, 6018016-24V, 6018017-36V, 6018012-48V This manual provides installation instructions for Cascade Clamp Open Guard. The kit prevents the accidental opening of the roll clamp when the paper roll is in the lifted position. The kit is designed for use with Cascade F and G-Series Paper Roll Clamps and D-Series Sliding Arm Clamps. WARNING: Do not use the Clamp Open Guard with any product other than a Pivot Arm Paper Roll Clamp and D-Series Sliding Arm Clamp. Display Limit Hoist Assembly Solenoid in Clamp Open Circuit AC0450.ill Part No. 6017376-R6 cascade corporation For Technical Support... To Order Parts... Call: 1-800-227-2233 Call: 1-888-227-2233 OR OR Write: Cascade Corporation, P.O. Box 20187, Portland, OR 97294 Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH 45505
Installation 1 Disconnect the cable from the positive battery terminal. 1 Remove cable from positive battery terminal. 2 Locate and install the hoist pressure switch assembly on the truck cowl or under the floorboard. Watch for clearance when the mast is tilted back if mounting on the cowl. The pressure switch assembly has adjustment screws under the white caps that need easy access for final adjustment. Install a tee fitting in the mast hoist circuit between the mast lowering control valve or drop stop valve (if equipped with AFC) and truck hoist control valve. Install a No. 6 hose between the tee fitting and the hoist pressure switch assembly end port. IMPORTANT: When installing the Clamp Open Guard with Cascade s Adaptive Force Control (AFC), the tee fitting must be installed between the drop stop valve and truck hoist control valve. NOTE: If an accumulator is installed in the mast hoist circuit, it provides a convenient location to tap into the hoist circuit. AC0201.ill Hoist pressure switch assembly Hoist supply 2 Install the hoist pressure switch assembly. Assembly AC0491.ill Mast Cylinder AFC Drop Stop (if equipped) No. 6 Hose Mast Lowering Control Hoist Control Clamp Auxiliary Hydraulic Pump Relief Tank AC0448.ill 2
Solenoid Attachment Revolving Connection Solenoid 1 2 Open Clamp 3 Install attachment supply hose to Port 1. 4 Install auxiliary valve hose to Port 2. Hoist Control Clamp Auxiliary AC0492.ill Hydraulic Pump Relief Tank AC0447.ill 3 Locate and install the solenoid valve on the truck cowl. Watch for clearance when the mast is tilt all the way back. The valve is being installed in the clamp OPEN line from the auxiliary valve to the attachment. Connect control valve port 1 to the supply hose going to the attachment. IMPORTANT: When installing the Clamp Open Guard with Cascade s Adaptive Force Control (AFC), the solenoid valve must be installed between the truck auxiliary valve and the AFC valve. Install 5 display 4 Connect solenoid valve port 2 to the supply hose from the truck auxiliary valve clamp OPEN line. 5 Install the display on the truck dashboard, overhead guard, or any other easy-to-see location. 3 AC0471.ill
6 Mount the freelift limit switch to the mast outer upright top crossmember using a fabricated bracket. The roller end of the limit switch must contact the inner or intermediate upright top crossmember to determine when the mast carriage is above freelift. The switch plunger must be depressed when the mast is in freelift. The plunger must extend when the mast is above freelift. Use cable ties to secure the switch wires leaving the cable with slack for mast tilt. Protect the cable from pinch or shear points that could damage the cable. 6 limit Mount freelift switch 6 limit Mount freelift switch Inner Upright Crossmember AC0225.ill Outer Upright Top Crossmember CAUTION: Consult the Lift OEM for proper + power source connection. 7 Connect cable ends to the components as shown. 12V Systems Connect the fused positive wire from the cable harness to a 12V switched power source, and the ground wire to a chassis ground. 24V 48V Systems Connect the fused positive wire from the cable harness to the DC-to-DC converter positive output wire and the ground wire to the converter negative output wire. Connect a 24V 48V switched power source to the converter fused positve input wire and connect the converter input ground wire to a chassis ground. Check the cable routing for pinch points and clearance. Use wire ties as needed. Solenoid Display AC0556.ill Limit 7 Connect cable ends System Fuse Output DC-to-DC Converter (24V 48V systems only) Input 8 Reconnect the positive battery terminal to the battery. Assembly Chassis Ground Battery (or power bus) ed AC0449.ill Fuse Block 8 Positive Battery Terminal 4
Adjustment The following adjustments must be done with the attachment that will be used with this specific lift truck. 1 Test the installation before putting the truck in service. Initially when the truck key is ON, one of the lights on the display should be on. Check the wiring if the display is not lit. 2 Locate the white plastic cover on the hoist pressure switches. Remove the screw on the cover and pry off the cover. The hexscrew allows adjustment in step 3. Display Hoist es 3 Raise the mast into freelift (the carriage raised with the mast uprights not extended). Unplug the pressure switch cable connector for the freelift switch. If the light on the display goes off, reattach the connector and adjust the freelift switch. Turn the hexscrew in the pressure switch CCW until the amber light goes on, then turn back CW to just when the green light goes on and an additional 1/4 turn. Go to step 4. If the light on the display stays on, swap the freelift and mainlift cable connectors and repeat step 3. If the light on the display stays on after swapping cables, troubleshoot the wiring connections. 4 Raise the mast carriage above freelift (the inner mast upright extending above the top of the outer upright). Unplug the pressure switch cable connector for the main lift switch. If the light on the display goes off, reattach the connector and adjust the main lift switch. Turn the hexscrew in the switch CCW until the amber light goes on, then turn back CW to just when the green light goes on and an additional 1/4 turn. If the light on the display stays on, troubleshoot the wiring connections. If both lights on the display stay on, troubleshoot the solenoid wiring connections. AC0490.ill FREE LIFT Mainlift Operation When the green light is on, the clamp will open and close normally. When the amber light is on, the clamp will not open. During fast lowering of the attachment, the lights may flicker between amber and green, this is normal. In mast freelift or mainlift, lighter loads may not activate the pressure switch and the green light will remain on. NOTE: The system does not work like a drop stop valve that prevents load drop or jump when the clamp is opened. The green light does not indicate that the load has been lowered to its optimal position. Solenoid AC0557.ill Freelift Disabling System The Clamp Open Guard can be disabled by performing the following Steps: Disconnect the two hoses to the normally-closed solenoid valve and connect together with a union. Remove the main power fuse in the cable harness. The truck and attachment will now operate normally. To enable the Clamp Open Guard, reverse the above procedure. 5 AC0566.ill
4 Clamp Open Guard 8 5 3 9 1 6!@ 7 2 Wire connection WITHOUT converter System Fuse ed Circuit 5A min. Fuse Block 0 DC-to-DC Converter AC0565.ill Battery Chassis Grounds REF QTY PART NO. DESCRIPTION 6008230 12V Clamp Open Guard 6018016 24V Clamp Open Guard 6018017 36V Clamp Open Guard 6018012 48V Clamp Open Guard 1 1 6008231 Display 2 1 6008297 Wire Harness Power 3 1 6008301 Wire Harness Solenoid 4 2 6008304 5 1 6020882 Solenoid 6 1 6019797 Limit 7 1 6019833 Junction Block 8 2 6019836 Wire Harness 9 2 6013999 Fitting 10 1 6021069 DC-to-DC Converter 11 1 6004133 Lamp-Amber 12 1 6004132 Lamp-Green Converter not required for 12V system. 6
Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation Parts Sales 2501 Sheridan Ave. Springfield, OH 45505 Tel: 888-CASCADE (227-2233) Fax: 888-329-0234 Cascade Canada Inc. 5570 Timberlea Blvd. Mississauga, Ontario Canada L4W-4M6 Tel: 905-629-7777 Fax: 905-629-7785 Cascade do Brasil Rua João Guerra, 134 Macuco, Santos - SP Brasil 11015-130 Tel: 55-13-2105-8800 Fax: 55-13-2105-8899 EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell Artigianato 1 37050 Vago di Lavagno (VR) Italy Tel: 39-045-8989111 Fax: 39-045-8989160 Cascade (Africa) Pty. Ltd. PO Box 625, Isando 1600 60A Steel Road Sparton, Kempton Park South Africa Tel: 27-11-975-9240 Fax: 27-11-394-1147 ASIA-PACIFIC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, 661-0978 Tel: 81-6-6420-9771 Fax: 81-6-6420-9777 Cascade Australia Pty. Ltd. 1445 Ipswich Road Rocklea, QLD 4107 Australia Tel: 1-800-227-223 Fax: +61 7 3373-7333 Cascade Korea 121B 9L Namdong Ind. Complex, 691-8 Gojan-Dong Namdong-Ku Inchon, Korea Tel: +82-32-821-2051 Fax: +82-32-821-2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: +64-9-273-9136 Fax: +64-9-273-9137 Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 361026 Tel: 86-592-651-2500 Fax: 86-592-651-2571 Sunstream Industries Pte. Ltd. 18 Tuas South Street 5 Singapore 637796 Tel: +65-6795-7555 Fax: +65-6863-1368 Cascade India Material Handling Private Limited No 34, Global Trade Centre 1/1 Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune 411 030 (Maharashtra) India Phone: +91 020 2432 5490 Fax: +91 020 2433 0881 c Cascade Corporation 2012 05-2012 Part No. 6017376-R6